hickin



Sept. 24, 1963 R. J. HlcKlN Box CONSTRUCTION 2 SheetsSheet 1 Filed Jan- 3, 1962 Sept. 24, 1963 R. J. HlcKlN 3,104,793

Box CONSTRUCTION Filed Jan. 5, 1962 2 Sheets-Sheet 2 United States Patent O 3,104,793 BX CONSTRUC'HN Robert J. Hickin, Seville, Ohio, assigner to Packaging Corporation E America, Dover, Del., a corporation of Delaware Filed lan. 3, 1962, Ser. No. 164MB@ 9 Claims. (Cl. 229-17) This invention relates to containers, and more particularly relates to the construction of boxes having a reclosable pouring opening.

A Wide variety of owable commodities are supplied to consumers in cartons or boxes of the type normally formed from `a foldable, precut and prescored boxboard blank. Further, the nature of the packaged commodity and the quantity contained in a given box are often such that the entire contents of a box are not utilized by the consumer at one time. Rather, the boxes are intermittently opened, a part of the contents poured out, land the box then reclosed for storage until another portion of its contents is required `at some future time. This gives rise to a requirement for boxes that are electively closed and sealed during shipment and handling prior -to delivery to the consumer and which may be easily opened by the consumer, but which may be simply and eliectively reclosed and again reopened during intermittent usage of the contents by the consumer.

One development in this area has been to provide a tear-out plug defined by a weakened line, such as a line of perforations or an interrupted cu-t line, -in one side wall of a boxboard carton for forming a pour opening. A hinged ap is then Ialso provided and designed to overlie and be adhered to the plug. ln some prior art structures the overlying flap covers the weakened line delimiting the plug and, together with the plug, effectively seals the carton during handling and shipment. The consumer gains access to the contents of such cartons by forcibly raising the overlying iiap. Because of the securement of the ap to the plug and the weak attachment of the plug to the side wall, this tears the plug from its original position thereby opening a pour opening through the side wall. The adhesive bond between the ear ap and plug thus must transmit the force for tearing out the plug.

Boxes of this type are normally supplied to the packager in a collapsed tubular form. The packager then erects the box, places his commodity therein and closes the respective end flaps in appropriate sequence. As the ap overlying the tear-out plug is normally integral with one of the end flaps of Ithe box, it cannot be secured to the plug until the box is erected, and is pressed into adherent relation with the plug at that time. The contents of the box cannot be relied upon to resist the force applied when the glue flap is pressed yagainst the plug. Thus when the overlying ap is pressed toward the plug to obtain the adherent bond therebetween, the plug normally resists this force, and resists being separated from the surrounding portion of the side wall and being pushed inwardly into the carton, with yonly the same force as will ultimately resist the plug being torn from its position when a consumer wishes to open the package. If the plug is left only lightly secured to the surrounding side wall, it will readily yield to the force exerted via the overlying flap during the adhering operation. Poor adherence will then be yobtained between these two members, and the bond therebetween may part without removing the plug when the flap is raised. Also the plug might be prematurely torn from its closed position during the adhering step and the seal of the package destroyed. Conversely, if the plug is left firmly connected to the surrounding side wall, the plug will be hard to tear out of its 351164,7933 Patented Sept. 24, 1963 closed position, thus requiring more effort on the part of the consumer in raising the overlying flap and increasing the risk of failure of the bond between these two members without removal of the plug. It will be appreciated that two concurrent yand `apparently conflicting requirements are thus raised. First, the plug must be rather lightly attached to the surrounding side wall so that it may be easily torn from its position, and secondly, a good adhesive bond must be established between the overlying flap and the plug to insure that the plug will be torn out when the flap is raised by the consumer.

Another `and continuing problem in the manufacture vof containers is one of cost. As container-s of this type are normally suitable for packaging a single product, and are produced and consumed on a high volume basis, each savings of cost, either by way of savings of material or of labor involved, is important.

Accordingly, it is an object of this invention to overcome the diiliculties outlined above.

`It is an object of this invention to provide improved carton blanks for constructing boxes of the type described and which insure the obtaining of a good bond between the overlying flap and the tear-out plug when the box is erected, but wherein the plug may be lightly attached and easily removed in opening the box.

It is another object of this invention to provide an improved carton construction including a readily removable plug for forming an opening therein and yan overlying ear flap wherein the ear flap may be simply but firmly adhered yto the plug, but wherein the plug may be easily torn from its carton closing position.

:It is another object of this invention to provide an economical, improved carton blank construction with a minimum amount of stock material and in accordance with the foregoing objects.

`Further and additional objects will become apparent to those skilled in this art in light of the embodiments illustrated in the attached drawings, the following description, and the appended claims.

In carrying out this invention in one illustrative form, a foldable blank of semi-flexible sheet material is provided comprising a series of joined side wall panels, a plurality of end closure flaps extending from the top and botto-mk edges of the side Wall panels, and a Iglue flap which is integral with the free edge of the panel at one end of the series and adapted to the adhered to the concealed sur-face of a portion of the panel at the .opposite end of the series to complete the basic tubular from of a box. The panel at said opposite end of the series is lformed with a weekened line delimiting a plug for forming an opening therethrough, and the glue flap is of a length and configuration to extend into the projected area of the plug along the weakened line when the blank is folded. The glue flap `does not cover the opening defined by the plug but provides support for the plug, along its peripheral edge, against inward pressure such as is `applied when the overlying flap 4is pressed against the plug to obtain la good adhesive bond therewith. A hinged ap extends yfrom a side edge of one end flap to overlie and be adhered .to the plug when the box is erected.

By way of illustration and example, one embodiment of this invention is disclosed in the drawings, wherein:

FIG. 1 is a plan view of an improved 4box blank employing teachings of this invention;

FIG. 2 is an enlarged partially broken away perspective view of an Iimproved box formed from the blank of FIG. 1 and employing teachings of this invention;

FIG. 3 is a perspective View illustrating a 'blank as in 1 as partially assembled lfor -forrning ya box as in HG. 4 is an enlarged partially broken away elevational view of a portion of the box of FIG. 2;

FIG. 5 is a cross-sectional view taken along line 5 5 of FlG. 4 and looking in the direction of the arrows;

FIG. 6 is a cross-sectional view taken along line 6-6 of FIG. 4 and llooking in the direction of the arrows; and

FIG. 7 is an enlarged perspective view of a portion of a box as in FIG. 2 subsequent to opening of the pouring outlet of `the box.

Referring no-w to the drawings, the illustrated box 1l) is of generally rectangular shape and is formed from blank 11 which includes four integrally joined side wall panels 12, 13, 14 and 15, side forming panels 13 and 15 being of somewhat greater lateral dimension than the end forming panels 12 and 14. These panels are integrally joined along scored fold lines 16, 17 and 1S. End liaps 19, 20, 21 and -22 are .integrally joined to wall panels 12, 13, 14 and 15, respectively, along a scored fold line 23, as shown. End ilaps 19, 20, 21 and 22 cooperate to form the bottom wall of box 1li. End flaps 24, 25, 26 and 27 are integrally joined to the opposite marginal portions of panels 12, 13, 14 and 15, respectively, along the scored told line 28 and cooperate to form a top wall 29'.

The end forming panel 12, at one end of blank 1v1, is forrned with a weakened line, such as a line of outs or perfor-ations 39, delimiting a lightly attached tear-out plug. The illustrated plug 31 is defined along three sides by an interrupted-cut line 30a and along its fourth side by a cut lline 28a corresponding to a portion of fold line 2S between panel i12 and end ilap 24.

At the edge of the blank opposite from panel 12, a glue Hap 32 is integrally joined to panel `15 along lfold line 33 and extends outwardly therefrom. A further ear or flap 34 of a Van Buren type or the like is joined `to end flap 27, also along edge or 4fold line 33, at 33a, and extends outwardly in the same direction as .glue llap 32. The ear flap 34 includes an integral tab portion 35 joined to the remainder of the ear ap along a scored fold line 36.

As indicated in FIG. 3, when blank 11 -is formed into a generally tubular shape preliminary to forming box 10, .the glue iiap 32 is positioned in underlying relation to the adjacent portion of panel 12 and is lirrnly adhered thereto by a suitable adhesive without being secured to plug 31. The vglue ap 32 is of suiiicient lateral dimension so Ias to extend over at least a part of plug 31, as ,j

illustrated in FlGS. 2, 4, 5 and 6. However, the flap 32 is formed with a notch or cut-out portion as at 37 whereby the lflap 32 projects into only a portion of the projected area delimited by the weakened line '30, as at 32a. It will be noted that the flap 32 thus extends behind a portion of the peniphery of plug 3-1 to lend substantial peripheral support to the plug against inward pressure but at the same time does not block ofi a major portion of the opening 38 left in side 12 when plug 31 is removed.

When blank 11 is further erected into a box as illustrated in FIGS. 2 and 4, the portion 33a of fold line 33 is disposed over the edge of plug 3x1 along cut line 28a, and the flap 34 extends over the exposed surface or" plug 31. ln the illustrated embodiment flap 32 extends behind one side edge of the plug and also behind a portion of the edge of the plug furthest removed from fold line 23 and hence furthest removed yfrom hinge line 33a of flap 34. This is an important feature, since it provides substantial support along a peripheral portion of the plug furthest from the hinge axis.

Flap 34 overlies plug 31 and extends lbeyond weakened line 30 thereby concealing such line and preventing ingress or egress of particles through the perforations or slits of such line. The main body portion of flap 34, between `fold lines 33 and 36, is normally lightly adhered to panel 12, as by small patches of adhesive 39 at each side of plug 31, see HG. 6, and is firmly adhered to plug 31 by the use of a large area of adhesive 40. With the adhesive in place, firm pressure is brought to bear on iiap 3ft over plug 31, to insure the Aformation ot"l a strong bond therebetween. Tab` 35 is left free from wall 12 whereby it may be easily turned outward as a grip for raising flap 34- and tearing out plu-g 31 when the box is to be opened, or may be very lightly adhered to side 12 to maintain it in an out-of-the-way position..

` As iiap 32 is firmly adhered to side panel 12, the portion 32a of the flap which is exposed in opening 3S will lend firm support against inward movement of plug 31, thus permitting the application of adequate pressure against flap 3G :to insure la good adhesive Ibondbetween flap 34 and plu-g 31. At the same time, portion 32a is sufhciently narrow to prevent substantial blockage or closing off .of the opening 38 whereby the contents of the box may be readily poured through opening 38 when the box is opened, as illustrated in FIG. 7. Portion 32a may be printed, both to insure that the plug 31 does not adhere to this area and to enhance the appearance'of the package when opened. v Formation of glue iiap 32 and ear liap 34 along the same side of the blank makes eiiicient utilization of the material from which blank 11 is formed. Flap 32 isr formed yfrom a portion of the material which would be cut away and disposed of from beneath ilap 34 if iiap'32 were formed at the opposite side of the blank. The con` struction of this invention also facilitates economical production of the improvedbox as the plug rein-forcing member is an element already present and necessary in the j box construction,'thus not requiring the presence of a `separate special reinforcing member.

Ear iiap 3d and glue flap 32, in the illustrated embodi-V ment, are of different lengths, as measured transversely to fold line 33, whereby these two flaps may 'be selectively i engaged by appropriate folding apparatus in assembling this box, such as to separately `apply glue to iiap 32 and` to form the blank into its basic tubular box form without also applying lglue to and inadvertently adhering liap34 at the same time. apparatus, the carton is passed into a folding device in a flat position generally as shown in FIG. 3. A station-ary fold-ing rod then catches the ear flap and bends it upward to an out-of-the-way position without engaging or raising theglue flap 32. The carton then travels over a -glue wheel which applies glue to flap 32 with-out also applying glue to liap 34. Subsequently, suitable rods or belts fold the remaining portions of the carton into gluing position and apply pressure to secure glue iiap 32 to the concealed surface of the adjacent portion of wall 12, thereby forming the basic tubular carton form.

ltl will be obvious that other modifications of the specific embodiment shown may 'be made in light of this disclosure without departing from the spirit and scopek of this invention. For example, depending somewhat upon the shape and positioning 'of plug 31, yand thus'of opening 38, glue ap 32 may extend beyond flap 34 and extend around a greater portion of the peripheral edge of plug 31. Y

it will thus be seen that improved carton blank and box constructions have been provided which are simple and economical but which meet the objects of this invern tion in providing for firm adhesive engagement, under applied pressure, between the overlying ap and the tear-out plug, but which also provide for a lightly engaged plug For instance, in one type of assembly by the appended claims to cover -any such modifications as fall within the true spirit and scope of this invention.

1 claim:

1. A foldable carton blank of sheet material comprising a wall section provided, adjacent la rst marginal portion thereof, with a plug substantially delimited by a weakened line to effect an opening through said section, a glue tlap foldably connected to a second marginal por- -tion of said section for adherence to the concealed surface of said iirst marginal portion when said carton `is in Vfolded condition, said glue flap having a peripheral segment thereof of predetermined conguration Vfor extending into the projected area delimited by said weakened line when said glue flap is adhered -to said concealed surface, and an ear ap foldably connected to a third marginal portion of said section for registration with and adherence to the exposed surface of said plug.

2. The foldable carton blank as recited in claim 1 wherein the configuration of said ear flap is such that no portion of the weakened l-ine delimiting said plug is exposed when `said ear ap is adhered to the exposed surface of said first marginal por-tion.

3. The foldable carton blank recited in claim 1 wherein a portion of the peripheral segment of said glue flap is extendable into said projected area at the portion of the weakened line furthest removed from the -fold line of said ear flap when said ear -ap is in position for adherence to the exposed surface of said plug.

4. The foldable carton blank recited in claim 1 wherein the fold line .between said third marginal portion and ear flap is -in substantial alignment with the fold line between said glue ilap and said second marginal portion when said blank is unfolded.

5. A foldab'le `carton blank as in claim 1 and wherein the fold lines of said ear flap and glue ap are in substantial alignment when said blank -is flat, and wherein one of said flaps extends a greater distance from the fold line thereof than said other ap.

6. A oldable carlton blank 'of sheet material comprising a side wall section having oppositely disposed mar- 6 ginal portions, a plug disposed adjacent one foi said marginal portions and substantially delimited by a weakened lin-e to elfeot an opening through said section, a glue flap foldably connected to the second of said marginal portions yfor adherence to the concealed sunface of said one marginal portion when said carton is in folded condition, said ghle ap having a peripheral segment thereof of predetermined configuration for extending int-o the projected area delimited by said weakened line when said glu-e ap is adhered tto said concealed suitfaoe, an end iiap foldably connected to a third mamginal portion intermediate said foppositely disposed manginal portions, and an ear ilap foldably connected to said end flap Yfor registration with and adherence to the exposed surface of said plug.

7. A carton having a side wall and including a glue flap adhered to a portion of the concealed surface of said side wall, said pontion of said side 'wall formed with a plug substantially delimited by a weakened line for forming an opening theiethrough, and a l[hinged flap adhered to the exposed sumface of said plug, a peripheral segment of said lgliue flap extending into the projected anca delimited by said rwea-kened line.

8. 'The carton as frecite'd in claim 7 and wherein said hinged liiap covers said lweakened line and includes a tab extending from its distal end.

9. The cart-on as recited in claim 7 and wherein a portion of the peripheral segment of said glue ap extends into said projected area at the portion of said weakened line tliurthest removed `rom the hinege line :of said hinged ap.

References Cited in the file of this patent UNITED STATES PATENTS 2,689,643 Willits Sept. 2l, 1954 2,735,605 Read Feb. 21, 1956 2,819,831 Polarek et al. Ian. 14, 1958 FOREIGN PATENTS 233,475 Australia Mar. 10, 1960 

1. A FOLDABLE CARTON BLANK OF SHEET MATERIAL COMPRISING A WALL SECTION PROVIDED, ADJACENT A FIRST MARGINAL PORTION THEREOF, WITH A PLUG SUBSTANTIALLY DELIMITED BY A WEAKENED LINE TO EFFECT AN OPENING THROUGH SAID SECTION, A GLUE FLAP FOLDABLY CONNECTED TO A SECOND MARGINAL PORTION OF SAID SECTION FOR ADHERENCE TO THE CONCEALED SURFACE OF SAID FIRST MARGINAL PORTION WHEN SAID CARTON IS IN FOLDED CONDITION, SAID GLUE FLAP HAVING A PERIPHERAL SEGMENT THEREOF OF PREDETERMINED CONFIGURATION FOR EXTENDING INTO THE PROJECTED AREA DELIMITED BY SAID WEAKENED LINE WHEN SAID GLUE FLAP IS ADHERED TO SAID CONCEALED SURFACE, AND AN EAR FLAP FOLDABLY CONNECTED TO A THIRD MARGINAL PORTION OF SAID SECTION FOR REGISTRATION WITH AND ADHERENCE TO THE EXPOSED SURFACE OF SAID PLUG. 